Ground Safety Review – Phase II September 8-10, 2008 Phil Mott AMS-02 Ground Handling Equipment (GHE) and Assembly Operations for the GHE Ground Safety Review – Phase II September 8-10, 2008 Phil Mott Phil Mott AMS-02 GSR Phase II

Documents Governing GHE Design KHB 1700.7C Space Shuttle Payload Ground Safety Handbook SW-E-0002E Ground Support Equipment General Design Requirements NASA-STD 8719.9 formerly NSS/GO-1740.9B Standard for Lifting Devices and Equipment Phil Mott AMS-02 GSR Phase II

Primary Support Stand (PSS) Used for payload integration and shipping Two configurations: Low & High Constructed with Aluminum 6061 Covers are Alumalite (painted aluminum face sheet with plastic corrugate) Factors of Safety 2 on yield 3 on ultimate Phil Mott AMS-02 GSR Phase II

Primary Support Stand (PSS) – Low Configuration Shipping Configuration 195” x 125” x 117” high Top Cover is removed as one piece Phil Mott AMS-02 GSR Phase II

Primary Support Stand (PSS) – High Configuration Assembly/Integration Configuration 195” x 125” x 166” high Phil Mott AMS-02 GSR Phase II

Primary Lifting Fixture (PLF) Used to lift the PSS and AMS-02 Welded steel A36 structure WLL: 26,800 lbs Factors of Safety 3 on yield 5 on ultimate Initial proof load to 2X WLL Annual load test to 1X WLL Phil Mott AMS-02 GSR Phase II

Multi Purpose Lifting Fixture (MPLF) Used to lift the Lower USS (LUSS) into place on the Upper USS and to lift the PAS into place for attachment Welded steel A36 structure WLL: 7000 lbs Factors of Safety: 3 on yield 5 on ultimate Initial proof load to 2X WLL Annual load test to 1X WLL Phil Mott AMS-02 GSR Phase II

Lower USS (LUSS) Shipping Fixture Used to ship/move/install the Lower USS Can be moved with forklift or crane/MPLF Welded steel A36 structure Phil Mott AMS-02 GSR Phase II

Can be moved with forklift, crane, air pallet, hand carts, or by hand Other Hardware Can be moved with forklift, crane, air pallet, hand carts, or by hand All lifting hardware will meet NASA-STD 8719.9 Master Dewar Transfer Dewar Valve Box L Valve Box S Control System (5 racks) Pumps (2) Heat Exchanger Hoses, Stands, Fittings, Etc Power Supply (2) Chiller PVVV Vacuum Pump UPS’s Numerous computers Toolboxes (2) Fans TRD GSE Air Supply/Compressor K Bottles Phil Mott AMS-02 GSR Phase II

Assembly Operations Phil Mott AMS-02 GSR Phase II

Arrival at KSC – Unload/Prep in the SSPF Airlock Crane PSS/Upper USS-02. Fork/Crane Lower USS-02 Fork/Crane all other Hardware including CGSE Phil Mott AMS-02 GSR Phase II

Arrival at KSC – Unload/Prep in the SSPF Airlock (cont) Phil Mott AMS-02 GSR Phase II

Move Into SSPF – Footprint 7 Crane or air pallet PSS/USS-02 Crane, fork, or air pallet all other hardware Phil Mott AMS-02 GSR Phase II

Unpacking Remove the upper cover from the PSS using the MPLF or slings Remove the side panels from the PSS Remove the cover from the LUSS Shipping Fixture Set up Cryosystem GSE (CGSE) Phil Mott AMS-02 GSR Phase II

PSS Preparation for AMS-02 Assembly/Integration Install Upper Columns and Beams on the PSS Phil Mott AMS-02 GSR Phase II

PSS Preparation for AMS-02 Assembly/Integration Raise the PSS/Upper USS-02 to the high position Install supports Phil Mott AMS-02 GSR Phase II

Installation of the Lower USS onto the Upper USS Fork the Lower USS under the Upper USS in the PSS Phil Mott AMS-02 GSR Phase II

Installation of the Lower USS onto the Upper USS (cont) Lift the Lower USS into position using the MPLF Position hydraulic jacks under the Lower USS for support and final positioning Attach Lower USS to Upper USS with pins and bolts Phil Mott AMS-02 GSR Phase II

Installation of the PAS Weight of PAS = 220 lbs PAS will be installed using the LUSS, overhead crane, and bottle jacks PAS EBCS Phil Mott AMS-02 GSR Phase II

Installation of the PAS (cont) Procedure similar to Lower USS installation – Details in work Place PAS on top of LUSS Shipping Fixture Place under payload using forklift Raise and rotate using bottle jacks Phil Mott AMS-02 GSR Phase II

Installation of the Keel Weight of Keel = 67 lbs Keel will be a 2 person manual lift and bolts installed by a 3rd person Phil Mott AMS-02 GSR Phase II